Automotive vehicle seat having a comfort system

ABSTRACT

There is disclosed a comfort system suitable for use in a seat of an automotive vehicle. The system preferably includes an air mover in fluid communication with an open space below a trim layer of the seat for providing ventilation, heating and/or cooling to the seat occupant.

CLAIM OF PRIORITY

This application claims the benefit of U.S. provisional application No.60/512,237, filed on Oct. 17, 2003, which is hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates generally to an automotive vehicle seat,and more particularly to an automotive vehicle seat having a comfortsystem configured for providing heating, cooling, ventilation, acombination thereof or the like to a passenger of the vehicle seat.

BACKGROUND OF THE INVENTION

For many years the transportation industry has been concerned withdesigning seats for automotive vehicles that provide added comfort tooccupants in the seats. Various innovations in providing seating comfortare discussed in U.S. Pat. Nos. 6,064,037; 5,921,314; 5,403,065;6,048,024 and 6,003,950, all of which are expressly incorporated hereinby reference for all purposes. In addition, other innovations inproviding seating comfort are discussed in U.S. patent application Ser.No. 09/619,171, filed Jul. 19, 2000, titled “Ventilated Seat Having aPad Assembly and a Distribution Device”; U.S. patent application Ser.No. 09/755,505, filed Jan. 5, 2001, titled “Ventilated Seat”; and U.S.patent application Ser. No. 09/755,506, filed Jan. 5, 2001, titled“Portable Ventilated Seat”, each of which are expressly incorporatedherein by reference for all purposes. In the interest of continuing suchinnovation, the present invention provides an improved comfort system,which is preferably suitable for employment within or as part of anautomotive vehicle seat and which assists in providing comfort controlto an occupant in the seat.

SUMMARY OF THE INVENTION

According to the present invention, there is disclosed an automotivevehicle seat. The seat typically provides an open space beneath anair-permeable trim surface of the seat. Preferably, the open space islocated between the trim surface and a cushion of the seat. An air moveris typically in fluid communication with the open space for moving airthrough the open space, the air permeable trim surface or both.

In one embodiment, the air mover is conveniently mounted upon orfastened to one or more components of the seat such as a lumbaradjustment assembly (e.g., lumbar wires or other guide members) of theseat or a frame of the seat. Advantageously, such components of the seatmay be a standard part of a particular seat or may be easily adaptablefor supporting the air mover such that minimal costs are added to theseat.

In alternative or additional embodiments, a tubular structure may assistin providing fluid communication between the air mover and the openspace. Advantageously, such a tubular structure can assist in allowingthe air mover to be more conveniently located relative to variousseating components.

BRIEF DESCRIPTION OF THE DRAWINGS

The features and inventive aspects of the present invention will becomemore apparent upon reading the following detailed description, claimsand drawings, of which the following is a brief description:

FIG. 1 is a side sectional view of a portion of an exemplary seataccording to the present invention;

FIG. 1A is an exploded perspective view of various layers and sub-layersof an exemplary comfort system according to an aspect of the presentinvention;

FIG. 2 is a perspective view of a portion of an exemplary air moveraccording to an aspect of the present invention;

FIG. 3 is a perspective partially cut-away view of an exemplary insert,which may be used according to the present invention;

FIG. 4 is a sectional view of the insert of FIG. 3 taken along line 4—4;

FIG. 5 is a rear cut away perspective view of an exemplary backrestcomponent with an air mover assembly and an exemplary tubular structureassembled thereto.

FIG. 6 is a perspective view of an exemplary fastener, which is employedfor attaching the air mover assembly to a seat.

FIG. 7 is a top perspective view of another exemplary tubular structurebeing assembled to an exemplary partially cut away seat component of avehicle seat.

FIG. 8 is a bottom perspective view of the exemplary seat component ofFIG. 7 during assembly.

FIG. 9 is another bottom perspective view of the exemplary seatcomponent of FIG. 7 after assembly.

FIG. 10 is a rear perspective view of an exemplary blower assemblyaccording to the present invention.

FIG. 11 is a front perspective view of the exemplary blower assembly ofFIG. 10.

DETAILED DESCRIPTION OF THE INVENTION

The present invention is predicated upon providing an automotive vehicleseat configured for providing heating, cooling, ventilation or acombination thereof to an occupant in the seat. The seat typicallyincludes an open space beneath an air-permeable trim surface of theseat. Preferably, the open space is located between the trim surface anda cushion of the seat. An air mover is typically in fluid communicationwith the open space for moving air through the open space, the airpermeable trim surface or both. In one embodiment, the air or otherfluid mover is conveniently mounted upon or fastened to one or morecomponents of the seat such as a lumbar adjustment assembly (e.g.,lumbar rods or wires) of the seat or a frame of the seat.Advantageously, such components of the seat may be a standard part of aparticular seat or may be easily adaptable for supporting the air moversuch that minimal costs are added to the seat. In alternative oradditional embodiments, a tubular structure may assist in providingfluid communication between the air mover and the open space.Advantageously, such a tubular structure can assist in allowing the airmover to be more conveniently located relative to various seatingcomponents. In other additional or alternative embodiments, the seat mayinclude a barrier layer disposed between the trim layer of the seat andthe open space.

Referring to FIGS. 1 and 1A, there are illustrated portions of a seatcomponent 10, which could be a backrest cushion component or a seatcushion component according to the present invention. The seat component10 typically includes a seat cushion 12, a trim layer 14 and an openspace 16 therebetween. In the embodiment depicted, the seat component 10also advantageously includes a forward layer 20, which may include abarrier sub-layer, a heater sub-layer or both. In another embodiment,the layer 20 may be located between open space 16 and the seat cushion12. As used herein, seat cushion is used to refer to both the cushionupon which the occupant sits and to the cushion against the occupant maylean, i.e. the backrest cushion.

The trim layer 14 may be formed of any materials suitable for automotivevehicle seats such as cloth, perforated and non-perforated leather,combinations thereof or other like materials. In a preferred embodiment,the trim layer 14 is formed of a perforated leather having openings(e.g., through-holes) suitable for having fluid (e.g., ambient air,heated air, cooled air or a combination thereof) flow therethrough. Inone embodiment, the leather is tanned or otherwise treated in a mannerto maintain a relatively high moisture content, reduce its thermalinsulation value effectively allowing it to alter its intrinsic specificheat so that the leather maintains less thermal energy. Also, suchleather may permit the number of openings in the perforated leather maybe reduced or eliminated.

The cushion 12 may also be formed of any material suitable forautomotive vehicle seats. Exemplary materials includes foams (e.g.,polymer/isocyanate foams) or other cushion materials. The cushion orcushion material include an air-impermeable barrier between the cushionand the open space. The air-impermeable barrier typically covers atleast the portion of the cushion that is used by an occupant, althoughthe barrier may be located on other portions of the cushion including onany through passages or sub-passages in the cushion. The barrier mayadditionally or alternatively include a coating material applied to thematerial of the cushion, a separate lining material that may be attachedto the cushion or a space layer a chemically treated a surface of thecushion (e.g. a skin), or any combination thereof.

The open space 16 may be provided in a variety of ways, but is typicallyprovided by positioning a spacer layer 24 between the seat cushion 12and the trim layer 14. The spacer layer 24 is typically formed of aspacer material and the spacer material may be selected from a varietyof different materials. The spacer material may be provided as a varietyof synthetic materials such as plastic or polymeric materials, paddingand stuffing materials, lining and carrier materials, combinationsthereof or the like. Preferably, the spacer material is at leastpartially pliable or flexible. As examples, the spacer layer may beprovided as a plurality of rubber, foam, plastic or other members orfibers. The members or fibers are preferably spaced apart from eachother to define the open space 16 therebetween while still being closeenough together to provide cushion and support. As another example thespacer layer may be formed of a 3-dimensional spacer fabric structure ormaterial.

The particular spacer layer 24 shown is formed of polymeric (e.g.,polyester) strand material that is interwoven to provide opposinghoneycomb structures 28 (e.g., fabric panels), which are interconnectedby several additional polymeric strand materials to provide the openspace 16 between the structures 28 while still providing cushion andsupport. As an example, one preferred material is sold under thetradename 3MESH® and is commercially available from Müller Textil GmbH,Germany or Müller Textiles, Inc., Rhode Island, USA.

As discussed, the forward layer 20, when included, can have a barriersub-layer, a heater or heater sub-layer or both. In the embodimentdepicted, the forward layer 20 includes a heater sub-layer 32, which ispreferably laminated to a gas barrier sub-layer 34 (e.g., a film, atextile or otherwise) although neither are necessarily required. Variousdifferent types of heaters are suitable for incorporation into a carseat and it is contemplated that any of such heaters may be incorporatedinto the seat of the present invention. Such heaters typicallyincorporate flexible electrical heating elements that are preferablythin, flat, non-obtrusive or a combination thereof. As examples, alay-wire heater, a carbon fiber heater, a positive thermal coefficient(PTC) heater, a thermoelectric heater or the like, which are typicallysupported with a backing (e.g., a cloth or fabric type backing) may beused. In a preferred embodiment, the heater sub-layer is a carbon fibertype heater with a backing (e.g., a nonwoven layer). One exemplarypreferred heater is sold under the tradename CARBOTEX® and commerciallyavailable from W.E.T Automotive Systems, Inc. in Germany and/or FTGFraser-Technik GmbH, Schleizer Strasse 56–58, D-95028 Hot/Saale,Germany. An example of such a heater is disclosed in U.S. Pat. No.6,064,037, issued May 16, 2000, herein expressly incorporated byreference for all purposes.

When included, the barrier sub-layer 34 is typically formed of a plasticor polymeric material that softens or melts upon exposure to heat toassist the sub-layer 34 in adhering to one or more other layers orsub-layers. Alternatively, the barrier sub-layer 34 may be formed offabrics, woven materials (e.g, goretex or microfibers), nylon, foam,including closed pore foam or other materials. Preferably, the barriersub-layer 34 is substantially impermeable to fluids and particularly airsuch that the sub-layer 34 can assist in forming an air barrier as willbe described further herein. Dimensionally, for a film barriersub-layer, it is preferable for the film thickness to be about 0.1 mm toabout 2.0 mm thick and more preferably about 0.7 mm to about 1.0 mmthick. Of course, it is contemplated that a film sub-layer may have avariable thickness and may be outside of the aforementioned ranges.

As mentioned above, gas barrier sub-layer 34 also may be located betweenthe open space and the cushion. In this aspect, the barrier sub-layerpreferably provides a barrier adapted to prevent fluid flow through orinto the cushion. In another embodiment, multiple similar or differentsub-layers are utilized.

The forward layer 20 can also include one or more buffer sub-layers, oneor more adhesives or adhesive sub-layers, one or more tape sub-layers,one or more porous foam layers or a combination thereof. Adhesive may besupplied in layers, drops or in a variety of other configurations.Preferably, the buffer layer is at least partially formed of aninsulating material.

In the preferred embodiment depicted, the forward layer includes twoadhesive sub-layers 38, one strip of tape 40 and one buffer sub-layer44. The adhesive sub-layers 38 are preferably formed of a hot meltadhesive although not necessarily required. The adhesive may be providedas a web or otherwise and may be continuous or non continuous (e.g., maybe applied in drops, dabs or the like). The adhesive sub-layers mayinclude polyamides, polyesters, elastomers, urethanes, olefin polymersor a combination thereof. Moreover, the adhesives may be formulated asdesired for particular processing parameters or conditions. Preferably,the adhesive sub-layers are substantially free of anti-blockingsolutions, blowing additives, process contaminants or the like whichmight interfere with adhesive performance. As an example, one suitablehot melt adhesive is commercially available as a non-woven web under thetradename SPUNFAB® from Spunfab, Ltd. 175 Muffin Lane, Cuyahoga Falls,Ohio 44223.

The buffer sub-layer 44 in the embodiment depicted is a layer of gauzewhich is capable of protecting the heater sub-layer 32 although variousalternative protective materials may be used such as cloth, fleece orthe like. Optionally the buffer sub-layer 44 may include adhesivematerial for laminating it to other sub-layers. The tape 40, when used,is preferably tacky on two sides.

It is also contemplated that the seat component 10 may include a secondopen space (not shown) provided between the barrier sub-layer 34 and thetrim layer 14, although not required. Thus, it is contemplated that theforward layer 20 may also include a spacer layer (not shown), which maybe located between the buffer sub-layer 44 and an occupant of the seat.The air-permeable layer, which may be any one of a variety ofair-permeable materials (such as reticulated foam, for example) may beable to help distribute air under the occupant. It is also contemplatedthat such a spacer layer may be formed of any of the other materialsdescribed in relation to the other spacer layer 24. In such anembodiment, the heater sub-layer 32, when provided, may be above orbelow the second open space.

Generally, it is contemplated that the various layers and sub-layersdescribed above may be combined in a variety of sequences and accordingto a variety of protocols and technique. Thus, the order in which thevarious layers and sub-layers are combined and the techniques ofcombining should not in any way limit the present invention unless suchorder or techniques is specifically claimed. It is also contemplatedthat there may be greater or fewer layers and that each layer mayinclude greater or fewer sub-layers. Moreover, it is contemplated thatthe layers may be secured between the cushion and trim layer using avariety of techniques.

The layers and sub-layers discussed, may be provided by a bag-type or aperipheral edge sealed insert such as that shown in FIGS. 3 and 4. Anexample of such an insert is described in U.S. patent application Ser.No. 10/434,890, filed May 9, 2003 and expressly incorporated herein byreference. Alternatively, however, the layers may be provided in anon-sealed condition or as an open edge insert as depicted in FIGS. 1and 1A such that there is no added peripheral seal about the spacerlayer 24.

According to a preferred method, the sub-layers of the forward layer areeach laminated to each other followed by laminating the forward layer tothe spacer layer. Of course, the forward layer and the spacer layercould be laminated together at the same time that the sub-layers of theforward layer are laminated together. Referring to FIGS. 1 and 1A, theforward layer is formed according to a preferred method by feeding thevarious sub-layers 32, 34, 38, 44 to a laminator (e.g., a belt androller laminator).

The sub-layers 32, 34, 38, 44 are preferably fed to the laminator fromrolls or otherwise and are cut to shape to form the forward layer afterlamination. The forward layer 20 may be cut to nearly any desired shapeor configuration. In the illustrated embodiment, the forward layer 20 iscut to be generally rectangular and to include a plurality ofthrough-holes 48. The through-holes 48 may be arranged in a generallyrectangular configuration or any other configuration and may each besubstantially the same size or differently sized. In FIGS. 1A and 3,however, the through-holes 48 are shown in a preferred configuration asprogressively becoming larger from one side of the forward layer toanother. The through-holes 48 are optional especially for layers andsub-layers that are not located between the spacer layer and theoccupant. Indeed, in some embodiments, the sub-layer, e.g. barriersub-layer, does not have through-holes.

Once the spacer layer 24 has been appropriately cut or otherwise shapedto the proper configuration, which preferably corresponds to the forwardlayer 20, the forward layer is laminated to the spacer layer 24. Ofcourse, it is contemplated that the forward layer 20 and the spacerlayer 24 may be laminated to each other prior to cutting the layers.

In the preferred embodiment, the layers 20, 24 are laminated in astationary lamination device at elevated temperatures such that theadhesive sub-layer 38 of the forward layer 20 adheres and attaches theforward layer 20 to the spacer layer 24 (e.g., the honeycomb structure).As such, laminating of the layers and cutting of the layers may beintegrated into a single processing step. For example, it iscontemplated that supplies (e.g., rolls) of each of the layers 20, 24may be provided to a machine that laminates the layers 20, 24 togetherand cuts the layers 20, 24, to the desired configuration. Alternatively,such cutting may be performed by another cutting machine or device. Insuch an embodiment, it is contemplated that the through-holes in theforward layer 20 may be formed prior to, during or after lamination.

It is also contemplated that additional cutting or laminating steps mayalso be employed. For example, it is contemplated that the layers, thesub-layers or both may be partially cut or shaped prior to stationary orother lamination and further cut or shaped after such lamination.

During final assembly, for embodiments including the heater sub-layer32, a wire harness or other electrical connection is preferably insertedwithin a pocket formed by the tape or otherwise attached to the forwardlayer 20. For assembly of the layers to a vehicle seat, the laminatedlayers are preferably connected (e.g., sewn, adhered or otherwiseattached) to a portion of the seat such as the cover (e.g., a perforatedleather cover) or to the cushion (e.g., foam) of the seat. In onepreferred embodiment, a seat cover may be configured to include a pocketfor receiving the layers. Alternatively, it is contemplated that hookand loop fasteners may be utilized to attach the layers to portions(e.g., the cover or foam cushion) of the seat. For example, a strip ofhook and loop fastener may be attached (e.g., adhered) to the spacerlayer and another strip of hook and loop fastener may be attached (e.g.,adhered) to the foam cushion within a trench. Thus, the strips can befastened to each other thereby attaching the layers 20, 24 to thecushion 12. The forward layer 20 is preferably closer to the outer seatcover relative to the spacer layer 24 although not necessarily required.

Generally, the present invention provides for fluid communicationbetween an air mover and the open space 16. In one embodiment, the airmover may be in direct fluid communication with the open space. In otherembodiments, however, a tubular structure is provided for facilitatingfluid communication between the air mover and the open space 16.

It is contemplated that a variety of air movers may be employedaccording to the present invention. Exemplary air movers include,without limitation, blowers, fans, pumps combinations thereof or thelike. Air movers of the present invention may be configured for movingheated air, cooled air, ambient air or a combination thereof. As anexample, an ambient air mover might be a fan or blower that pushes orpulls air from inside the vehicle cabin through the open space of thecomfort system. A heated or cooled air mover might be, for example, ablower or fan coupled with a heating and/or cooling unit (e.g., athermoelectric heater, cooler or both) wherein the unit heats or coolsair from the cabin of the vehicle prior to pushing the air through theopen space of the system to the trim surface of the seat. In oneembodiment, the air mover may be coupled with a heating and/or coolingunit in a single integrated component. For example a thermoelectricelement may comprise on or more parts of a blower or fan, (e.g. as partof the blades). For example, as seen in U.S. Pat. Nos. 6,119,463;6,223,539; and 6,606,866, all of which are incorporated by reference.

The air mover may be positioned in a variety of locations relative tothe components of the seat for allowing it to move air through the openspace of the system and/or for allowing it to move air through the trimlayer of the seat. The air mover may be directly adjacent the open spaceprovided by the spacer material. In such an embodiment, the air movermay be located in a recess of the occupant side of the seat cushion andmay provide direct fluid communication between the open space of thesystem and an opening (e.g., a through-hole) in the seat cushion.Alternatively, the air mover may be located at least partially betweenthe seat cushion component and the backrest component for providingfluid communication between the open space and the air mover, theinterior of the vehicle cabin or both. In addition, the air mover may belocated within the seat cushion remote from the occupant side i.e.enclosed within at least a minimal amount of seat cushion material, onthe underside of the seat cushion or remote from the backrest e.g. nearthe front of the seat cushion.

One or more structures may facilitate fluid communication between an airmover and the open space. For example, one or more passages orsub-passages may be formed within, through or on the seat cushion forforming a tubular structure that provides fluid communication betweenthe open space and the air or other fluid mover through the opening. Asdiscussed above, the passages may be coated or lined to improve theirair-impermeability. Such passages and sub-passages may also includestructures or features that reduce the collapse of the passages andsub-passages under the weight of the occupant. Typically, the passagewill be centrally located, e.g. along either the front-to-back orside-to-side centerline of the cushion, so as efficiently distribute airfrom the air mover; however, this is not necessarily the case. Thispassage may be located anywhere on the seat (e.g. proximate or within athigh bolster) such as along the front or back edges of the seat oralong either side edge. The passage may also be located in any quadrantof the cushion.

Alternatively, additional components may be employed to provide fluidcommunication between the air mover and the open space. Examples of suchadditional components include, without limitation, tubes or tubularstructures formed of materials such as polymers, foams, fabrics,adhesives, metals, fibrous materials, combinations thereof or the like.

For embodiments including a tubular structure, the tubular structure mayextend behind the seat cushion, to the underside of the cushion, to alocation within the cushion or elsewhere. When extending to the air orother fluid mover, the tubular structure may extend around the seatcushion, extend between two or more seat cushions or portions of seatcushions, extend through a portion or the entirety of the seat cushion(e.g. a through-hole), a combination thereof or the like. Also, morethan one tubular structure may be utilized. When multiple tubularstructure are utilized, one or more air or other fluid movers may beutilized and the tubular structures may be the same or different in themanner in which they extend to the air or other fluid mover. Moreover,it is contemplated that the tubular structure may be shaped as desiredto assist it in extending to a desired location behind the seat cushion.For example, the extension may be arced, angled, contoured, straight orotherwise configured as it extends away from the rest of the insert.

Referring to FIG. 5, there is illustrated a seat backrest component 54having a system in accordance with the present invention. Like in FIG.1, the system of FIG. 5 includes the spacer layer 24 for forming theopen space 16 and, optionally, includes the forward layer 20. In theembodiment depicted, the spacer layer 24 overlays a forward surface 56of a backrest cushion 60 of the backrest component 54. Of course, thelayer 20, 24 may be attached to the cushion 60 or a cover or trim layerusing any of the attachments disclosed herein. The system also includesa tubular structure 62 for providing fluid communication between theopen space 16 and an air mover 66.

As shown, the backrest cushion 60 has an opening 68 (e.g., a slot orthrough-hole) extending generally through the cushion 60 of the backrestcomponent 54. In particular, the opening 68 extends through the forwardsurface 56 and a rearward surface 72 of the cushion 60 at a central areaof the cushion 60. In the embodiment shown, the opening 68 is sized toreceive the tubular structure 62 and the tubular structure 62 extends atleast partially or fully into and through the opening 68 and the cushion60 preferably substantially seals (e.g., interferingly seals, adhesivelyseals or otherwise seals) about an outer surface of the tubularstructure 62. Alternatively, however, it is contemplated that thetubular structure 62 may not extend into the opening 68 and that thestructure 62 is otherwise situated (e.g., abuttingly adhered) to formsubstantially fluid tight communication between the tubular structure 62and the opening 68. The tubular structure 62 also extends behind thecushion 60 to oppose at least a portion of the rearward surface 72 ofthe cushion 60. In the embodiment shown, the tubular structure 62extends to the air mover 66 (e.g., a blower or blower assembly), whichis also located behind the cushion 60. As can be seen, the tubularstructure 62 is generally flexible thereby allow the structure 62 to becontoured (e.g., curved or angled) to extend to and/or through theopening 68.

Referring to FIGS. 7–9, there is illustrated an alternative system witha seat cushion component 78 having the spacer layer 24 for forming theopen space 16 and, optionally, includes the forward layer 20 analternative tubular structure 80 according to the present invention. Aswith previous systems, the tubular structure 80 can be configured in amanner similar to any of the tubular structures described herein,however, the tubular structure 80 is additionally contoured (e.g., arcedor angle) or non-linear. In particular, the tubular structure 80 extendsfrom a first end portion 84 to a second end portion 86 with a contoured(e.g., arced, angled or non-linear) portion 88 therebetween. Preferably,the contoured portion 88 arcs to allow at least the second end portion86 to be of the tubular structure 80 to substantially coextend or becomesubstantially parallel with a side edge 42 of a cushion 94. It should berecognized that the tubular structure 80 is naturally contoured (e.g.,arced, angled or non-linear), which as used herein means that thecontoured portion is contoured without external forces required tocreate the contoured portion.

As shown in cut-away, the seat cushion 94 has an opening 98 (e.g., aslotted through-hole) extending generally through the cushion 94 of theseat cushion component 78. In particular, the opening 98 extends througha forward surface 102 and a rearward surface 104 of the cushion 94 at aside area of the cushion 94. In the embodiment shown, the opening 98 issized to receive the tubular structure 80 and the tubular structure 80extends at least partially or fully into and through the opening 98 andthe cushion 94 preferably substantially seals (e.g., interferinglyseals, adhesively seals or otherwise seals) about an outer surface ofthe tubular structure 80. Alternatively, however, it is contemplatedthat the tubular structure 80 may not extend into the opening 98 andthat the structure 80 is otherwise situated (e.g., abuttingly adhered)to form substantially fluid tight communication between the tubularstructure 80 and the opening 98. The tubular structure 80 also extendsbehind the cushion 94 to oppose at least a portion of the rearwardsurface 104 of the cushion 94.

In the embodiment shown, the tubular structure 80 extends to an airmover 66 (e.g., a blower assembly or blower), which is also locatedbehind the cushion 94. As an added advantage, the contoured portion 88allows the tubular structure 80 to easily extend toward a forward edge112 of the seat cushion 94 and/or seat cushion component 78. It shouldbe understood, however, that such a contoured portion 88 may beconfigured to allow the tubular structure 80 to extend toward anydesired location.

It should be understood that in any of the embodiments disclosed herein,steps used to assemble the system to a seat may be carried out in anydesired order. For example, the spacer material may be attached to thecushion followed by extending the tubular structure through the cushionopening. Alternatively, the tubular structure may be extended throughthe cushion first.

Generally, the air mover (e.g., the blower or blower assembly) may beattached as needed or desired to various different components of thevehicle seat or to other portions of the vehicle depending upon the seatconfiguration, the vehicle configuration or both. For example, the airmover may be attached to a cushion of the seat (e.g., a seat or backrestcushion), a frame of the seat, one or more rod supports of the seat, oneor more location adjustment components of the seat, one or more framesupports for the seat, combinations thereof or the like. It is alsocontemplated that the blower may not be attached to any components otherthan the tubular structure.

Preferably, the air mover is attached to a component that maintains asubstantially identical location with respect to a seat or backrestcushion particularly during adjustment of the cushion position or seat.Of course, it is contemplated that the location of the air mover maychange relative to the seat or backrest cushion as well.

It is also contemplated that the air mover may be attached to componentsof the seat or other portions of the vehicle with a variety of fasteningmechanisms. For example, the air mover may be attached to the variouscomponents with one or more mechanical fasteners such as clips, rivets,screws, bolts, interference fit fasteners, snap fit fasteners, integralfasteners, non-integral fasteners, combinations thereof or the like.Other fasteners which may be employed include adhesives, tapes, magnets,combinations thereof or the like.

Depending on the desired configuration, the one or more fasteners may beintegrally formed with the air mover (e.g., the housing or othercomponents of a blower) or the one or more fasteners may be separatelyformed from the air mover and attached thereto. Alternatively, amounting structure may be attached to the air mover and the one or morefasteners may be integrally formed with the mounting structure or theone or more fasteners may be separately formed from the mountingstructure and attached thereto. When used, the mounting structure may beattached to the air mover using any of the fasteners or fasteningmethods disclosed herein with respect to the air mover and the seat. Itis also contemplated that the mounting structure may be integrallyformed with one or more of the seat components discussed herein.

Referring to FIGS. 10 and 11, there is illustrated one exemplary airmover or blower assembly 130 according to the present invention. Theassembly 130 includes the blower 66 attached to a mounting structure132. Of course, the blower 66 may be configured for moving heated air,cooled air, ambient air or a combination thereof.

In the particular embodiment shown, the blower 66 includes a housing 136(e.g., a plastic housing) that is attached to the mounting structure 132with a plurality of fasteners 138 (e.g., screws). The mounting structure132 is shown as a substantially rectangular metal plate with rounded offcorners 142 and a plurality of openings 144 (e.g., through-holes)extending through the plate, one opening 144, adjacent each corner 142.Of course, it is contemplated that a variety of structures other thanplates may be employed as the mounting structure and a variety ofmaterials (e.g., plastics, fabrics or the like) may be employed forforming the structure in a variety of alternative configurations.

The assembly 130, as shown in FIG. 5 also includes one or more (e.g.,four) fasteners 150 attached thereto. As shown in FIG. 6, each fastener150 includes a body portion 152 with projections 156,158 extendingtherefrom for interference fitting the fastener 150 to the mountingstructure 132. In the embodiment shown, each fastener 150 includes apair of projections 156 extending from an end 162 of the fastener 156and a conical projection 158. Preferably the pair of projections 156 andthe conical projection 158 extend at least partially toward each other,although not required.

Each fastener 150 also includes a fastening mechanism 166 for attachingthe fastener 150, the blower assembly 130 or both to one or morecomponents of the seat or other portions of the automotive vehicle.Preferably, the fastening mechanism 166 can be attached by interferencefit, adhesion, magnetism or otherwise. In the particular embodimentdepicted, the fastening mechanism 166 is a C-shaped clip configured forforming an interference fit. It is generally contemplated that thefastening mechanism may be fitted with a locking mechanism (not shown)to enhance the ability of the fastening mechanism 166 in attaching tomembers.

In FIG. 5, the air mover assembly 130 is attached to a pair of members170 that extend substantially parallel to the back surface 72 of thebackrest cushion 60 or backrest cushion component 54. As shown, themembers 170 extend substantially vertically when the backrest component54 is in the upright position, although they may extend in a variety ofdirections depending upon the members 170 employed and the seatconfiguration. In the particular embodiment illustrated, the members 170are cylindrical metal rods that form a portion of a lumbar or backsupport adjustment assembly. Preferably, the members 170 aresubstantially stationary relative to the backrest component 54, althoughthis is not required.

In addition to the above, it is contemplated that the air mover 66 orair mover assembly 130 might be attached to various different componentsof a lumbar support adjustment assembly. For example, the air mover 66or air mover assembly 130 may be attached to plates, flexible members,fasteners, motors or other components of such an assembly.

For attaching the air mover assembly 130 to the members 170, the end 162and projections 156 of the fasteners 150 are extended through theopenings 144 of the mounting structure 132 until the mounting structure132 is interference fit between the pair of projections 156 and theconical projection 158. Also, the fastening mechanisms 166 of each offasteners 150 are interference fit (e.g., at least partially clippedabout) the members 170.

As shown, the mounting structure 132 is between the members 170 and thecushion 60. In an alternative embodiment, however, the mountingstructure 132 may be located on a side of the members 170 away from thecushion 60. In such an embodiment, the fasteners 150 would have to bereversed such that the fastening mechanisms 166 extend toward thecushion 60 and the air mover 66 would be located at least partiallybetween the members 170. Advantageously, such an embodiment can providefor greater space between the air mover 66 and the cushion 60 forallowing air to flow to or from the air mover 66 more easily.

Referring to FIGS. 10 and 11, the air mover assembly 130 is attached toa support frame 174 for the cushion 94. As depicted, the mountingstructure 132 is attached to the support frame 174. It is contemplated,however, that the air mover 66 may be directly attached to the supportframe 174 and the mounting structure 132 may be removed. Moreover, thesupport frame 174, particularly when molded of plastic, can be molded tospecifically receive the air mover 66 and assist in its attachmentthereto.

Any one of the tubular structures of the present invention may be placedin fluid communication with the air movers of the present inventionusing a variety of different techniques, fastening mechanisms or thelike. As an example, a tubular structure may be fastened (e.g., adhered,mechanically fastened, magnetized, combinations thereof or the like) toan air mover or another component to provide fluid communication.Preferably, although not required, fluid communication is established bypositioning the tubular structure relative to the air mover such thatthe air movers can pull air from or push air into an opening (e.g., atunnel or passage) defined by the tubular structure.

According to one embodiment, the air mover 66 (e.g., the blowerassembly) of FIGS. 5 and 8, is preferably attached to an attachmentcomponent 180 (e.g., a ring) of the respective tubular structures 62, 80for placing the air mover in fluid communication with the tubularstructures. Additionally, the tubular structures 62, 80 include anopening 186 (e.g., a through-hole) extending in fluid communication withan internal opening 190 (e.g., a tunnel) of the tubular structures 62,80. At least partially surrounding the openings 62, 80 are attachmentcomponents 180, which are attached (e.g., adhered) to the tubularstructures 62, 80.

In the embodiment shown, and with additional reference to FIG. 2, thehousing 130 includes flanges 194 suitable for snap-fitting the housing136 to the attachment component 180. In this manner, the air mover 66can be attached to and placed in fluid communication with the tubularstructures 62, 80 and can, in turn, be placed in fluid communicationwith the through-holes 48 of the forward layer 20, the open space 16 ofthe spacer layer 24.

Advantageously, the attachment component 180 and flanges 194 can providea unique and efficient method of attaching the air mover to the tubularstructure. It is contemplated however, that various other methods ofattachment (e.g., fasteners, sewing, mating threaded attachments, quickconnects or the like) may be used to attach the air mover to the tubularstructures. It is also contemplated that the attachment component 180and the housing 136 and flanges 194 of the air mover may be variedwithin the scope of the present invention.

While is contemplated that any of the tubular structures may be attachedto the air mover using the attachment component 180 of FIG. 2, it isalso possible to design a ring, which aids in the assembly of thetubular structure to the blower. As an example, there is an attachmentcomponent 200 (e.g., a ring) illustrated in FIG. 11 having an extension204 (e.g., a semi-circular extension) extending from the component 200and a lip 208 located adjacent an interface of the component 200 and theextension 204. As shown, the extension 204 extends away from the ringcomponent 200 in the same plane as the component 200 and the lip 208extends from the extension 204 at least partially perpendicular to theplane of the attachment component 200 and the extension 204. Thus, thelip 208 is configured for extending outwardly away from any tubularstructure into which the component 200 is installed.

To assemble the component 200, and the tubular structure when attachedto the component 200, to the air mover 130, the lip 208 can beabuttingly engaged with the housing 136 of the blower 66 adjacent anedge 212 of the housing 136. In turn, the component 200 is aligned withfasteners 220 of the air mover 66 such that the component 200 may besnap-fit to the fasteners 220 as described previously with regard to thecomponent 180 of FIG. 2.

It should be recognized that various alternative attachments other thanthe rings described may be employed to attach the air movers to thetubular structures. For example, attachments such as twist locks, springlocks, tabs on a ring, tabs on the air mover housing, combinationsthereof or the like may be employed. It should be further recognizedthat the air mover, the snap ring or both can include protectiveequipment such as fingerguards (e.g., cross-bars) or the like.

Operation

In operation, the comfort system of the present invention can preferablyprovide heating, cooling, ventilation or a combination thereof to anoccupant of a seat having the insert. In one embodiment, heating isprovided by inducing electrical current (e.g., from the automotivevehicle battery) to travel through the heater sub-layer 32 such that theheater sub-layer 32 provides heat to the trim layer 14, an occupant ofthe seat or both. Alternatively, heating may be provided by warming orheating air (e.g., with a thermoelectric air mover) and moving the airvia the air mover through one of the tubular structures 62, 80, the openspace 16, the openings 48 in the forward layer 20, the opening 186 inthe tubular structures and ultimately to the trim layer 14, the occupantor both.

If ventilation is desired, the air mover can be operated to pull air orpush air through the trim layer 14, the openings 48 in the forward layer20, the open space 16, the openings 186 of the tubular structures 80 ora combination thereof. Such air preferably flows at least partially pastthe occupant of the seat and before of after flowing through the seatcover (e.g., a perforated leather seat cover or cloth seat cover)thereby providing ventilation to the occupant and providing convectiveheat transfer from the occupant to the flowing air. If cooling isdesired, the air pushed toward the trim layer 14, the occupant or bothmay be cooled by cooling air (e.g., with a thermoelectric air mover) andmoving the air through the tubular structures, the open space 16 or bothand ultimately to the trim layer, the occupant or both. It should beunderstood that cooling, ventilating, heating or a combination thereofmay be controlled by the control unit.

In embodiment having a heater sub-layer, it may be preferable for onlythe heater sub-layer 32 or the ventilation or cooling system to berunning at one time, however, it is contemplated that both may beoperated simultaneously. Moreover, it is contemplated that both theheater sub-layer 32 and the ventilation or cooing system may be operatedat various levels (e.g., 2 or more levels of output) such as by havingan air mover that can operate at different levels or by having variouslevels of electricity flowing through or throughout the heater sub-layer32.

It is also contemplated that one or more temperature sensors (e.g., athermostat, a thermistor or the like) may be included adjacent theheater sub-layer, the trim layer or the like. Preferably, anytemperature sensors are near a seating surface of the seat closelyrelated to (e.g., at or near) a temperature being experienced by anindividual in the seat. Such temperature sensors may be in signalingcommunication with the control unit such that the control unit cancontrol the air mover, the heater sub-layer or both for attaining ormaintaining a desired temperature at areas adjacent the individualand/or the temperature sensor. Moreover, the control unit may beprogrammed with instructions for commanding the air mover, the heaterlayer or both to change output levels (e.g., turn on or turn off) if thetemperature sensor senses a temperature above or below one or morethreshold levels. An example of such programming is described in acopending patent application titled “AUTOMOTIVE VEHICLE SEATING COMFORTSYSTEM”, Ser. No. 60/428,003, filed Nov. 21, 2002 and incorporatedherein by reference for all purposes.

Unless stated otherwise, dimensions and geometries of the variousstructures depicted herein are not intended to be restrictive of theinvention, and other dimensions or geometries are possible. Pluralstructural components can be provided by a single integrated structure.Alternatively, a single integrated structure might be divided intoseparate plural components. In addition, while a feature of the presentinvention may have been described in the context of only one of theillustrated embodiments, such feature may be combined with one or moreother features of other embodiments, for any given application. It willalso be appreciated from the above that the fabrication of the uniquestructures herein and the operation thereof also constitute methods inaccordance with the present invention.

The preferred embodiment of the present invention has been disclosed. Aperson of ordinary skill in the art would realize however, that certainmodifications would come within the teachings of this invention.Therefore, the following claims should be studied to determine the truescope and content of the invention.

1. A ventilated seat for a vehicle, comprising: a vehicle seat having aseat cushion component and a backrest cushion component, at least one ofwhich is ventilated, each ventilated component having an air-permeabletrim surface at occupant contact areas of the seat; an open spacelocated beneath the trim surface of at least one of each ventilatedcomponent; and an air mover assembly in fluid communication with theopen space, wherein the air mover assembly is fastened to a back supportadjustment assembly with one or more members that extend substantiallyvertically when the backrest cushion component is in an upright positionand wherein the one or more members comprise a pair of lumbar rods. 2.The ventilated seat of claim 1 wherein the ventilated component includesan opening extending therethrough for at least assisting in providingfluid communication between the air mover assembly and the open space.3. The ventilated seat of claim 1 wherein the air mover assemblycomprises a thermoelectric unit.
 4. The ventilated seat of claim 1,further comprising a heater layer.
 5. The ventilated seat of claim 1further comprising a tubular structure at least partially providingfluid communication between the air mover assembly and the open space.6. The ventilated seat of claim 5, wherein the tubular structure extendsentirely through the seat cushion.
 7. The ventilated seat of claim 6,further comprising a snap-fit configuration for attachment of thetubular structure with the air mover assembly and wherein the tubularstructure is flexible.
 8. The ventilated seat of claim 5, furthercomprising a snap-fit configuration for attachment of the tubularstructure with the air mover assembly and wherein the tubular structureis flexible.
 9. The ventilated seat of claim 8, wherein the tubularstructure extends entirely through the seat cushion.
 10. A ventilatedseat for a vehicle, comprising: a vehicle seat having at least oneventilated component with a seat cushion or a backrest cushion, eachventilated component having an air-permeable trim surface at occupantcontact areas of the seat; an air mover assembly including a mountingstructure and a plurality of fasteners attached to the mountingstructure wherein at least a portion of the air mover assembly isattached to one or more components behind the seat cushion or thebackrest cushion; a tubular structure providing fluid communicationbetween the air mover assembly and an open space, the open space beinglocated beneath the trim surface of each ventilated component, andprovided by a spacer layer; wherein the air mover assembly is in fluidcommunication with the open space and, wherein the one or morecomponents behind the seat cushion or backrest cushion are metal rodsthat are part of a lumbar or back support adjustment assembly and theplurality of fasteners are attached to the metal rods.
 11. Theventilated seat of claim 10 wherein the ventilated component comprisesthe backrest cushion component.
 12. The ventilated seat of claim 10wherein the lumbar or back support adjustment assembly comprises atleast a portion of a frame of the seat.
 13. The ventilated seat of claim10 wherein the one or more metal rods are substantially stationaryrelative to the backrest cushion.
 14. The ventilated seat of claim 10wherein the air mover assembly comprises a blower that is fastened to apair of the metal rods.
 15. The ventilated seat of claim 10 wherein thelumbar or back support adjustment assembly comprises a lumbar adjustmentassembly.
 16. The ventilated seat of claim 10, wherein the seat cushionor backrest cushion includes an opening extending therethrough, and thetubular structure extends at least partially into the opening.
 17. Theventilated seat of claim 10, further comprising a snap-fit configurationfor attachment of the tubular structure with the air mover assembly andwherein the tubular structure is flexible.
 18. The ventilated seat ofclaim 10, further comprising a heater layer.
 19. The ventilated seat ofclaim 10, further comprising a thermoelectric device.
 20. A ventilatedseat for a vehicle of claim 10, wherein the air mover assembly isattached to the metal rods via at least one fastener; wherein the atleast one fastener includes a body portion with projections extendingback from a first end of the fastener, a conical projection extendingforward towards the first end, the projections and conical projectionsadapted to secure to the air mover assembly and a second end adapted toremovably join with the metal rods.
 21. The ventilated seat of claim 10wherein the lumbar or back support adjustment assembly further comprisesone or more of plates, flexible members, fasteners, motors orcombinations thereof.
 22. The ventilated seat of claim 21 wherein theair mover assembly comprises a blower that is fastened to the one ormore plates, flexible members, fasteners, motors or combinationsthereof.
 23. A ventilated seat for a vehicle, comprising: a) a polymericfoam cushion; b) at least one through-hole passage that extends throughthe cushion; c) an air-permeable trim surface disposed over the cushionat occupant contact areas of the seat; d) a peripheral edge-sealedinsert for providing an open space beneath the air-permeable trimsurface; e) a plurality of sub-passageways for facilitating aircommunication between the open space and an air mover, the air mover influid communication with the open space of the insert through thethrough-hole passage and the sub-passageways; f) a flexible electricalheater layer; g) a thermoelectric unit coupled with the air mover; h) aprogrammable control unit for operating the air mover; i) at least onetemperature sensor in signaling communication with the programmablecontrol unit; j) a tubular structure that extends through thethrough-hole passage and attaches to the air mover; and k) a lumbar orback support adjustment assembly.
 24. The ventilated seat of claim 23,further comprising a heater layer.
 25. A ventilated seat for a vehicle,comprising: a) a polymeric foam cushion; b) at least one through-holepassage that extends through the cushion; c) an air-permeable trimsurface disposed over the cushion at an occupant contact area of theseat; d) a peripheral edge-sealed insert for providing an open spacebeneath the air-impermeable trim surface, an air permeable polymericlayer disposed between the cushion and the air-permeable trim surface;e) a plurality of sub-passageways for facilitating air communicationbetween the open space and an air mover, the air mover in fluidcommunication with the open space of the insert through the through-holepassage; f) an upper layer of the insert that includes a film or atextile and has a plurality of openings therein; g) a thermoelectricunit coupled with the air mover; h) a programmable control unit foroperating the air mover; i) at least one temperature sensor in signalingcommunication with the programmable control unit; j) a tubular structurethat extends through the through-hole passage and attaches to the airmover; and k) a lumbar or back support adjustment assembly to which theair mover is attached.
 26. The ventilated seat of claim 25, furthercomprising a heater layer.
 27. The ventilated seat of claim 25, whereinthe upper layer of the insert includes an adhesive layer thereon.